Repairing Filler Holes With A Metal-Spray Machine - Sprayin' Metal

1/13We met Ed West on the cruise to the Mopar Nationals. Ed's ride is a trick custom Dodge Ram truck. Discussing the smooth-filled seams of the truck, Ed gave us the lowdown on his metal spraying business and how effective it is at filling in bodywork applications. Here, Ed points out where the fuel-fill door has been seamed into the fender of his truck. It sounded good enough to go and have a look.

You never know what you'll come across on the run to the Mopar Nationals. This year, taking the drive from Chicago to Columbus, we met Ed West. Ed was riding in his highly customized Hemi Orange Dodge Ram truck, and we got to talkin' bodywork. When Ed described his RustBuster's operation in Nebraska, we were intrigued by what we heard. At first, we were a little skeptical, but as Ed told of the process, we wanted to know more. Essentially, the system involves spraying pure metal into a repair or fill area, using a specially manufactured metal-spray machine. Zinc or a zinc alloy is arced at the tip of the gun, and then the molten plasma is rapidly propelled onto the prepared repair area, fusing with a mechanical bond. Zinc has a natural affinity for steel and acts like a corrosion barrier, and in fact, the repair material actually galvanizes the steel.

The process sounded as though it would have some very useful applications in resto and custom bodywork; from filling and repairing holes and seams to building up areas as a filler. Ed related that the material could be shot on as required, either paper-thin or as thick as needed, depending on the repair. After making the repair, the filler can be worked much like lead, though it is harder and more durable than typical plastic repairs. It sounded good enough to make the trip to Nebraska for a first-hand look. We were impressed by what we saw.